GrowSpan 24' Wide Series 500 Tall High Tunnels with Roll-Up Sides Photo may show a building of a different length and style. Frame shown includes roll-up sides and customer-supplied baseboards. Actual cover material may differ. Building shown is equipped with an optional roll-up end. 2017 All Rights Reserved. Reproduction prohibited without permission. 24' Wide Series 500 Tall High Tunnels: All Standard Lengths. 1
Important Information LOCATION Choosing the proper location is an important step before you begin. The following suggestions and precautions will help determine whether your selected location is the best location. READ THIS DOCUMENT BEFORE YOU BEGIN TO ASSEMBLY Thank you for purchasing a Series 500 high tunnel structure. When properly assembled and maintained, this product will provide years of reliable service. These instructions include helpful hints and important information needed to safely assemble and properly maintain the structure. Please read these instructions before you begin. If you have any questions during the assembly, please contact customer service for assistance. Never erect the structure under power lines. Identify whether underground cables and pipes are present before preparing the site, setting ground posts (if equipped), or anchoring the structure. Location should be away from structures that could cause snow to drift on or around the building. Do not position the structure where large loads such as snow and ice, large tree branches, or other overhead obstacles could fall. Always check local building codes before you begin and follow codes as instructed. SAFETY PRECAUTIONS Wear eye protection. Wear head protection. Wear gloves when handling metal parts. Use a portable GFCI (Ground Fault Circuit Interrupter) when working with power tools and cords. Do not climb on the frame during or after construction. Do not occupy the structure during high winds, tornadoes, or hurricanes. Provide adequate ventilation if the structure is enclosed. Do not store hazardous materials in the structure. Provide proper ingress and egress to prevent entrapment. SITE After choosing a location, proper preparation of the site is essential. Follow the information below. A level site is required. The site must be level to properly and safely erect and anchor the structure. Drainage: Water draining off the structure and from areas surrounding the site should drain away from the site to prevent damage to the site, structure, and contents of the structure. WARNING: The individuals assembling this structure are responsible for designing and furnishing all temporary bracing, shoring and support needed during assembly. For safety reasons, those who are not familiar with recognized construction methods and techniques must seek the help of a qualified contractor. SETTING THE GROUND POSTS The frame assembly of this building requires the setting of all ground post in concrete. Review the layout diagrams for additional details. Enlist the services of a professional and competent contractor to prepare the site and set the ground posts. Failing to secure ground posts in concrete as required may result in damage to the building, building contents, and surrounding property. 2 S500_24_Wide_HT_Roll_up
Important Information ASSEMBLY Following the instructions as presented will help ensure proper assembly. Failing to follow these steps may result in an improperly assembled and anchored structure. NOTE: Once the main frame is assembled, many of the remaining procedures can occur simultaneously, depending on available assistants and equipment. Before you begin, review all technical documents to better understand overall building design. The steps outlining the basic frame assembly are as follows: 1. Verify that all parts are included in the shipment. Notify Customer Service for questions or concerns. 2. Read this guide and all additional documentation included with the shipment before you begin. 3. Gather the tools, bracing, ladders, lifts, and assistants needed to assemble the structure. 4. Check the weather before you install the roof cover and any end panels (if equipped). Do not install covers or panels on a windy or stormy day. 5. Re-evaluate the location and site based on the information and precautions presented in the documentation included with the shipment. 6. Prepare the site (if applicable). Set ground posts in concrete, or attach base plates to concrete. If building includes end framing, review those instructions and drawings for additional end framing requirements. 7. Assemble rafter components and rafter support kit components (if equipped). Optional support kits require an additional purchase. 8. Assemble main building frame (rafters, cabling, purlins, etc). 9. If used, attach baseboards and ribbon boards (customer-supplied). 10. Attach 111613Z144 aluminum channel along the sides for cover installation. Consult these instructions and all drawings for additional details. 11. Install end wall frame, door frame, and end wall cladding if equipped. 12. Attach 111613Z144 aluminum channel to the end rafters. 13. Install main cover. This applies to film or 5.2 oz cover material. 14. Install roll-up (or drop-down) sides and anti-billow ropes. 15. Complete and return all warranty information as instructed if present. REQUIRED TOOLS The following list identifies the main tools needed to assemble the shelter. Additional tools and supports may be needed depending on the structure, location, and application. Tape measure or measuring device and marker to mark locations on the pipes and rafters. Variable speed drills and impact drivers. (Cordless with extra batteries works best.) Metal-cutting saws or tools to cut pipe and aluminum. Drill bit set Wrenches and impact socket set, hammer, and gloves. Adjustable pliers and self-locking pliers. Ladders, work platforms, and other machinery for lifting designed to work safely at the height of the building. Safety equipment to protect head, eyes, hands and feet. UNPACK AND IDENTIFY PARTS The following steps will ensure that you have all the necessary parts before you begin to assemble the shelter frame. 1. Unpack the contents of the shipment and place where you can easily inventory the parts. Refer to the Bill of Materials/Spec Sheets. 2. Verify that all parts listed on the Bill of Materials/ Spec Sheets are present. If anything is missing or you have questions, consult the Pictorial Parts Guide and all diagrams for clarification, or contact Customer Service. NOTE: Do not open plastic bags containing smaller parts such as fasteners or washers at this time. Simply verify quantity. S500_24_Wide_HT_Roll_up 3
Baseboards and Ribbon Boards A customer-supplied baseboard is recommended for roll-up sides that include the stabilizer bar. A baseboard runs the length of the frame and provides a seal between ground level and the stabilizer bar. All baseboard and ribbon board material and fasteners to secure these to frame are supplied by the customer. See photo below. RIBBON BOARD FOR ROLL-UP SIDES OPTIONAL In some instances, a ribbon board is installed along the side of the frame. This is optional for buildings with roll-up side panels. Customer supplies the materials and fasteners for the ribbon board. End View Stabilizer Bar Baseboard FAH005B Bolt 111613Z144 Channel 5/16" Carriage Bolt (supplied by customer) FALB01B Nut FALF01B Fender Washer Secure baseboard (and ribbon board) joints between rafters as shown for best results. 2" x 6" Ribbon Board if used. (supplied by customer) Rafter Leg or Ground Post Inside of Shelter Outside of Shelter Ground Level Dimensions Recommended baseboard dimensions are 2" x 8" and ribbon board dimensions are 2" x 6" (minimum). Recommendation: Use two (2) carriage bolts (exterior finish) per rafter connection to secure the baseboards and ribbon boards to the rafter legs/ground posts. Actual frame shown in the examples above may differ. These are presented for illustration purposes only. 5/16" Carriage Bolt (supplied by customer) 2" x 8" Baseboard (customer supplied) DIAGRAMS ARE NOT TO SCALE. Ground Level 4 S500_24_Wide_HT_Roll_up
Parts Identification The following graphics will help identify the basic parts of the frame. (Some parts are not shown.) FA4482B Tek Screw FAG363B 3/8" x 3" Hex Bolt FAME08B 3/8" Flat washer FALB04B 3/8" Nut 100441 and 100443 Magnetic Nut Setter CC6212 Fabric Clip 102546 Cross Connector QH1070 Pipe Strap 103856 Band Clamp AS2167 Anchor Shackle 108503 Cable Bracket PGBRKAAS01 Bracket 103544 Mounting Plate (Roll-Up or Drop- Down Sides only) 103496 Gear Box (Roll-Up or Drop- Down Sides only) 102569 Roller Bearing (Roll-Up or Drop- Down Sides only) 111613Z144 Aluminum U-Channel 104189 Turnbuckle GS0049 Splice Plate 115249 End Rafter (Base Plates Only) 115250 Mid Rafter (Base Plates Only) S500_24_Wide_HT_Roll_up 5
Overview GrowSpan 24' Wide Series 500 Tall High Tunnels Sample building shows roll-up sides and optional roll-up door panel. (Wood for end frame is supplied by the customer.) OVERVIEW This section describes assembling your building frame. See illustration below to identify main parts. 1. Prepare site and set ground posts in concrete, or install base plates, depending on option. 2. Locate the required parts for each assembly procedure. 3. Assemble the rafters and main frame. Drawing may show a model of a different length. Refer to Quick Start section located near the back of this guide for on-center measurements and post layout. GROUND POST OPTION SHOWN BELOW AND IN MOST DIAGRAMS THROUGHOUT THIS GUIDE. SEE QUICK START SECTION FOR ADDITIONAL GROUND POST AND BASE PLATE DETAILS. Ridge Purlin Interior Rafter End Rafter Cable Cable Ground Post Side Purlin On-center Ground Level 6 S500_24_Wide_HT_Roll_up
Prepare and Square the Building Site PREPARE THE BUILDING SITE A level site is required to accurately and safely construct the building. Consult the services of a qualified contractor to properly grade and prepare the site. Site should slope away from the building for proper water drainage. After the site is prepared, mark the location of the frame corners to square the frame position. Taking these steps before assembling the shelter saves time and ensures that the structure is square and positioned as desired. SQUARE THE SITE: GENERAL STEPS 1. Identify a corner where a building rafter will be positioned, drive in a stake, and string a line the exact width of the building and stake in place. (Width of the rafter is measured from center-to-center of the rafter legs.) 2. After the first corner stake is in place, string a line the width of the building (center-to-center) and drive the second corner stake into the ground. 3. String a line at least as long as the building 90 from the line between the first and second stakes. The following procedures are suggested methods. Their use depends on the size of the shelter, shelter application, the footings (if applicable), and the method used to anchor the shelter. When in doubt, consult the services of a qualified contractor experienced with the construction of similar structures. Base Plates If your frame includes base plates, prepare the site and anchor the base plates to concrete before assembling the frame. Layout the site and continue with Base Plates Option section. Base plates can be anchored to a concrete slab or concrete piers. Consult Ground Post section for concrete pier layout, then continue with Base Plates section. Ground Posts If the frame includes ground posts, set all ground posts as described within this manual. Width of the shelter is measured from the center of one ground post to the center of the remaining ground post. Length is also measured center-to-center. If your building includes ground posts, continue with the Setting Ground Post section. SETTING THE GROUND POSTS NOTE: A transit can be used to ensure an accurate 90 angle, or the 3-4-5 rule can be used. Refer to diagram. Using multiples of 3-4-5 such as 6-8-10 or 12-16-20 helps to maintain an accurate 90 angle. 4. After squaring the position of the building, measure the length and drive the third corner stake. 5. Repeat the same step for the last corner stake. NOTE: The distance measured diagonally between corner stakes must be equal for the building to be square. The frame assembly of this building requires the setting of all ground post in concrete. Review the layout diagrams for additional details. Enlist the services of a professional and competent contractor to prepare the site and set the ground posts. Failing to secure ground posts in concrete as required may result in damage to the building, building contents, and surrounding property. S500_24_Wide_HT_Roll_up 7
Set Ground Posts MARK THE SITE AND DIG POST HOLES These steps describe marking all post hole locations and digging the holes. For some sites, it may not be possible to complete the procedure in this manner. An alternative procedure such as working from one end of the building toward the other may be necessary. Determine the best procedure based on the site and other factors and proceed as needed. NOTE: Refer to the Quick Start Section located near the back of these instructions for the Side Profile and related diagrams. Complete these steps: 1. Stake the outline of the building using string line and batter boards. Set batter boards 3' back from the building corners. Check to ensure that the building layout is square. Cover or panels (if equipped) will not install properly if the building frame is not square once assembled. 2. Consult the diagrams in the Quick Start section to verify the frame length and width dimensions and to accurately position the ground posts. 3. Guided by the string line, use a flag or stake to mark each ground post hole location. 4. Move the string line and dig a post hole a minimum of two feet (2') deep or to a depth that is below the geographic frost line. Consult local building codes. A power auger works best. Minimum hole diameter is 12". 5. After digging all holes, reattach the string line to the batter boards and use it as a guide to set and align the ground posts. Drawing may show layout of a different length. Refer to Quick Start section located in the back of these instructions for on-center measurements and post layout for your frame. on-center on-center on-center on-center 8 S500_24_Wide_HT_Roll_up
Set Ground Posts SET GROUND POSTS Required parts and equipment: Ground Posts (113334) and 103856 Band Clamps Equipment to level and brace posts NOTE: Concrete (customer-supplied) is required to secure all ground post in the holes. Set all posts at the same height for proper assembly. Position all rafter mounting holes to point toward the ends of the frame. Stake Ground Posts for Concrete Rafter mounting holes point towards ends. Set all posts at the same height. Additional bracing may be needed to keep the post plumb while concrete sets. Enlist the services of a qualified contractor to properly set posts. Here are the basic steps: 1. Take one ground post, measure 24" from the end opposite the single bolt hole, and mark the location on the ground post. Repeat to mark all ground posts. NOTE: The single rafter mounting bolt hole is to the top of the ground post. Position the two pre-drilled holes in the ground post toward the ground. 2. With assistance, brace all posts in place. See diagram below. All posts to be plumb before adding concrete. Use the baseboard mounting holes and customersupplied fasteners and stakes to hold posts in place. 3. Add concrete to anchor posts in holes. Fill hole so concrete remains below ground level. Customer-supplied braces and fasteners. Ground Level Set top of posts at the same height. Posts set in concrete 24" below ground level. SETTING THE GROUND POSTS The ground posts include pre-drilled rafter mounting bolt holes and holes to attach the baseboards. Position rafter mounting holes so they point to the ends of the frame. Baseboard attachment holes will then be positioned to point to the outside/inside of the frame. S500_24_Wide_HT_Roll_up 9
Set the Ground Posts Ground Level Ground Post 2 Deep Concrete In areas where frost is common, dig each post hole so it falls below the frost line. Minimum hole depth for all areas regardless of frost is 24". Minimum hole diameter is 12". Set all ground posts 24" below ground level. Consult local building codes and qualified contractors for additional details when digging the post holes and setting the ground posts. Follow established codes and construction practices. Optional: Before setting the posts, drill a hole through the bottom of each ground post 2"-3" from the end and insert a 6"-8" length of rebar through it. This will help stabilize and anchor the ground posts once the concrete sets. CONCRETE PIER 12" 10 S500_24_Wide_HT_Roll_up
Base Plates (Option) SETTING THE BASE PLATES For buildings equipped with base plates, secure the plates to either a concrete foundation or concrete piers prior to attaching the rafter legs and assembling the frame. Customer is responsible for construction of the necessary concrete foundation or concrete piers. Consult and follow local and regional building codes for slab requirements. Once concrete has cured, attach base plates. Ensure base plates are aligned and spaced according to layout diagram in Quick Start section located near the back of this guide. Attach using the appropriate mounting hardware (purchased separately). Plates must be aligned, plumb, and set at correct, uniform height for proper assembly. ATTENTION: Slide two (2) 103856 band clamps over each base plate of first two rafters at each end for side cable attachment. See circles below. Two (2) clamps. Two (2) clamps. Frame length may differ from diagram shown. Two (2) clamps here. Two (2) clamps here. 6' On-Center ATTENTION: Enlist the services of a qualified contractor to properly layout and set base plates. Diagrams not to scale. General Anchor Bolt and Epoxy (recommended) Installation Steps: 1. Using the Rafter Layout Base Plates diagram in Quick Start section, determine on-center positions of base plates. Use a string line to maintain alignment. 2. Square plate on foundation and mark bolt hole and base plate locations using base plate as a template. Concrete Concrete 3. Remove base plate and drill mounting holes according to requirements of customer-supplied anchor bolts. 4. Clean bolt holes according to anchor bolt specifications and directions on epoxy container. 5. Once holes are clean, set plate back in place and apply recommended epoxy into each hole as described by epoxy manufacturer. 6. Take anchor bolts (with nuts and washers installed) and carefully insert one into each bolt hole. Adjust nut and washer on anchor bolt to gauge how far bolt will drop into hole. 7. Allow epoxy to set according to manufacturer's instructions before tightening. 8. Repeat procedure to install remaining base plates. 115249 Corner Base Plate Align Marks 115250 Mid Base Plate 9. After epoxy has set, return to all anchor bolts and tighten according to manufacturer's instructions. Align Marks S500_24_Wide_HT_Roll_up 11
Rafter Assembly RAFTER ASSEMBLY After setting the ground posts, continue with the rafter assembly. Do not set assembled rafters into position on the ground posts until concrete has set. Check with contractor for set times. NOTE: All rafter assemblies consist of three main rafter sections. Consult the rafter diagrams in the Quick Start section of these instructions before and during the rafter assembly process for details. Assistance is required to assemble the rafters and frame. Assemble all main sections of rafters as described below and set aside. PG500TC2316S241 PG500TC2316S242 PG500TC23G16S03 PG500TC23G16S03 24' Wide Rafter STEP 1: Select the rafter pipes to assemble one rafter. STEP 2: Slide the separate pipe pieces together. STEP 3: Secure each rafter joint using two (2) Tek screws. STEP 4: Wrap each splice and Tek screws with duct tape to protect the cover. 12 S500_24_Wide_HT_Roll_up
Rafter Assembly Optional Support Kit RAFTER ASSEMBLY Optional Support Kits If the optional support kits were purchased, continue with the assembly steps that follow. Consult the diagrams supplied with the rafter support kits for additional details. See also the diagram in the Quick Start section of this guide. If the support kits were not purchased, continue with the frame assembly. ATTENTION: Support kit components are typically not installed for the end rafters when end wall framing is present. NOTE: If rafter with support kit is positioned where mid bay diagonal cables are located, use this bolt (each end) to secure 108503 cable bracket to rafter. See Page 23 and Quick Start diagrams for additional details. VIEW 2 WEB TO RAFTER CONNECTION BAND CLAMP (103856) BAND CLAMP (103856) WEB (ST07150D13G17S1) WEB (ST07150D13G17S1) BAND CLAMP (106735) BAND CLAMP (106735) 2'-0" 10'-6 7/16" GROUND LEVEL TO CENTER OF CROSS BEAM CROSS BEAM (S20P126G14SGA) VIEW 3 RAFTER TO CROSS BEAM CONNECTION VIEW 4 CROSS BEAM CONNECTION GROUND LEVEL VIEW 1 WEB TO CROSS BEAM CONNECTION CROSS BEAM (S20P126G14SGA) BAND CLAMP (106735) See Quick Start Section for View details. 24'-0" CENTER TO CENTER OF GROUND POSTS Complete these basic steps: 1. Slide the band clamps into position on the assembled rafter. 2. Assemble the 2" x 2" square tube cross beam. Position cross beam band clamps as needed before installing bolts. 3. Verify dimensions and position of support kit components and install web components. Cross beam will run parallel with the ground will installed properly. 4. Return to each band clamp and secure each clamp to the rafter using a Tek screw. Install Tek screw in a position that will not contact the cover when it is installed. GROUND POST OPTION SHOWN ABOVE AND IN MOST DIAGRAMS THROUGHOUT THIS GUIDE. SEE QUICK START SECTION FOR ADDITIONAL GROUND POST AND BASE PLATE DETAILS. ATTENTION: Depending on position, bracket for roof cable (108503) is secured using the mounting bolt that connects cross beam of support kit to the rafter. See cable positions on frame for additional detail. S500_24_Wide_HT_Roll_up 13
Frame Assembly FRAME ASSEMBLY Use the diagrams and information that follows to assemble the main frame. ATTENTION: Rafters are heavy. Always lift rafter from two separate points to prevent damage and injury. Examine the site to determine the best way to move the rafters into position and to set them onto the ends of each set of ground posts. Do not set rafters into position until the ground post concrete has set. Optional, but recommended especially for long buildings: Build a Rafter-Spacing Jig (Customer supplies materials.) A spacing jig saves time and helps to evenly space the rafters. Jig sets the on-center spacing of rafters. Examine the photo below and use it to build a jig to space rafters during purlin installation. Use 2" x 4" lumber and wood fasteners. Customer-supplied rafter-spacing jig. ATTENTION: Anchor the first rafter in place using bracing or rope/cable. Do not allow the first rafter to stand without bracing until additional rafters are set and purlins are installed. Connect rafter to ground post using: FAG363B (3/8") bolts, FAME08B washers, & FALB04B nuts. (2) 103856 Clamps (2) 103856 Clamps Rope or Cable (2) 103856 Clamps (2) 103856 Clamps Ground Level IMPORTANT! Slide two 103856 band clamps over each of the first two ground posts at each end of the frame. 14 S500_24_Wide_HT_Roll_up
Frame Assembly FRAME ASSEMBLY (continued) Use this diagram to properly position the purlins during the frame assembly. Side purlins will run just above the cross beam of the rafter support kit components if equipped. Center the ridge purlin on top of the rafters. Secure using the QH1070 and FA4482 Tek screws. Install one Tek screw through the side of the strap and into the purlin pipe. Secure side purlins at 11' above ground level. Secure purlin using QH1070 pipe straps at each end rafter. Use 102546 cross connectors at each mid rafter position. Approximately 11' Ground Level S500_24_Wide_HT_Roll_up 15
Frame Assembly FRAME ASSEMBLY (continued) After setting the first end rafter and bracing it in place, set the second rafter and add the purlins and purlin clamps. Consult the techincal diagrams for connection details. Diagrams show the optional rafter support package. Additional purchase required. Frame shown may differ from actual frame. Consult Quick Start guide for actual frame. Purlin Pipe After the first few rafters are set and connected by purlins, remove the end rafter bracing and continue with the frame assembly. Purlin Pipe IMPORTANT! Secure each QH1070 pipe strap to purlin pipe using one Tek screw. Secure all 102546 cross connectors to rafter and to purlin pipe using Tek screws. Secure all purlin pipe splices using two Tek screws. See photos on next page. 16 S500_24_Wide_HT_Roll_up
Frame Assembly FRAME ASSEMBLY (continued) End Rafter QH1070 Pipe Strap Purlin FA4482B Tek Screw Purlin FA4482B Tek Screw FA4482B Tek Screw Photo shows the installation of the side purlin and pipe strap at the end rafter. See Connection Details in Quick Start section for additional information. Ridge purlin is installed on top of the rafters unless noted. Secure each QH1070 pipe strap to the purlin pipe using one Tek screw. Purlin Pipe #2 FA4482B Tek Screws 102546 Cross Connector Purlin Purlin Pipe #1 End of Purlin Pipe #2 inside #1 Purlin Pipe Splice Mid Rafter (Between End Rafters) Secure all 102546 cross connectors to the rafter and to the purlin pipe using Tek screws. Secure each purlin pipe splice using two Tek screws. S500_24_Wide_HT_Roll_up 17
Frame Assembly FRAME ASSEMBLY (continued) Customer-supplied rafter-spacing jig. 18 S500_24_Wide_HT_Roll_up
Frame Assembly FRAME ASSEMBLY (continued) Frame with Ground Post Option (No Rafter Support Components) Frame shown may differ from actual frame. Consult Quick Start guide for actual frame. CABLE ASSEMBLY AND INSTALLATION IS SHOWN IN A LATER PROCEDURE. Frame with Ground Post and Rafter Support Components Frame with Base Plates Option (No Rafter Support Components) NOTE: Some frames may also include support components on end rafters. These examples do not. S500_24_Wide_HT_Roll_up 19
Baseboard Installation Recommended BASEBOARD INSTALLATION RECOMMENDED Gather the parts: 2" x 8" treated lumber (supplied by customer). 5/16" carriage bolts and nuts supplied by customer. Length depends on the thickness of the baseboard. When properly installed, baseboard runs the length of the frame at ground level. The baseboard is supplied by the customer. The following procedure describes one way to install the baseboards. The size and type of the baseboard you choose may require the use of alternative steps. On the outside of the frame, attach the first baseboard to the rafter using two (2) 5/16" carriage bolts and nuts. Countersink bolt heads if carriage bolts are not used. Continue adding baseboards to complete the first run. Baseboard Ground Level Ground Posts and Baseboard The above diagrams present examples only. Actual installation depends on customer-supplied materials and other factors. Splices are made between posts as shown in the drawing below. Use a short section of baseboard to secure separate baseboards at a splice. See diagram below. Repeat steps to install the second run of baseboard on the remaining side of the frame. NOTE: The boards should be at ground level or slightly into grade to create a good seal between the board and ground level. After installing the baseboards, continue with these instructions. Inside of Shelter Splice 5/16" Nuts Ground Level 5/16" Carriage Bolts Outside of Shelter 20 S500_24_Wide_HT_Roll_up
Diagonal Cable Installation Using the diagrams and photos, install diagonal cables at each end bay of the frame. Position turnbuckle either at the top end of the cable assembly as shown in the Quick Start diagrams, or at the bottom end (for easier adjustment) as shown in the photos on the next page. Secure each band clamp to the rafter using a Tek screw. Install Tek screw in a location that will not contact film cover when it is installed. Apply duct tape over band clamp on top of rafters to protect film. PGBRKAAS01 Bracket Shackle Turnbuckle Cable Cable PGBRKAAS01 Bracket CABLE ASSEMBLY PART NUMBERS (24' WIDE) END BAYS (SIDEWALL) CAB25G0702 MID BAYS (ROOF) CAB25G1502 104189 Turnbuckle AS2167 Anchor Shackle Complete these steps: PGBRKAAS01 Bracket 1. Consult the Cable Assembly table above (also found in the Quick Start guide) and choose a cable for the end bay sidewall location. Verify on-center rafter spacing to ensure correct cable is selected. 2. Construct a cable assembly using the components shown in the cable diagrams above. Ensure shackle is tighten after installation. 3. Fully open turnbuckle. Threads of threaded jaw should remain fully in turnbuckle body when properly opened. See below. End of Rod Body Photo shows installation of end bay sidewall diagonal cable assemblies with turnbuckles at the lower end. S500_24_Wide_HT_Roll_up 21
Diagonal Cable Installation CABLE ASSEMBLY AND INSTALLATION (continued) 4. For end bay sidewall cables, secure the upper band clamp 3"- 4" below the clamp of the lower purlin run. (See A below.) A 3"- 4" Purlin Clamp Steps 4 & 5 Lower Purlin Run A Lower Purlin Run B Band Clamp AS2167 shackle attached to crimped cable end. PGBRKAAS01 bracket attached to band clamp. Sample frame (above) showing installed cables. Frame has ground posts. Dashed lines show ground level. Steps 6 & 7 B ATTENTION: If band clamps were not installed as described on Pages 11 and 14, install those now. 5. Take cable assembly and attach one end to the band clamp. Depending on preference, attach either end to the band clamp. 6. Take remaining end of the cable assembly and use it to judge the position of the lower band clamp. Mark position on rafter and secure lower band clamp to rafter using a Tek screw. See B at the right. 7. Attach cable assembly to band clamp. 8. Repeat Steps 1-7 to construct and install the remaining seven (7) end bay sidewall cables. 9. Check to ensure each band clamp is secured to rafter tube using a Tek screw. Tape over clamp to protect film when it is installed. 10. Return to all cable turnbuckles and hand-tighten until snug to remove all slack. DO NOT OVER TIGHTEN CABLES. 11. Continue with the construction and installation of diagonal roof cables. See next page. Turnbuckle installed at the lower end of cable assembly and attached directly to bracket. Band Clamp Secure band clamp to pipe. Lower photos show attaching the PGBRKAAS01 bracket to the installed band clamp. 22 S500_24_Wide_HT_Roll_up
Diagonal Cable Installation In addition to the end bay sidewall diagonal cables, this frame includes mid bay roof diagonal cable assemblies. Consult the frame connection diagrams in the Quick Start section near the back of this guide for all connection details. See Cable Assembly table on Page 21 (and in Quick Start section) for cable part number. PARTS TO ASSEMBLE AND INSTALL MID BAY CABLES IMPORTANT: Review all connection detail diagrams in the Quick Start section to better understand how to install these cable assemblies and 108503 brackets. FAME18B 3/8" Washers FALB04B 3/8" Nuts FAG365B 3/8" x 3-1/2" Bolt A A 104189 Turnbuckle B B AS2167 Anchor Shackle 108503 Cable Bracket PROCEDURE 1: INSTALL 108503 CABLE BRACKETS Unlike end bay sidewall diagonal cables, mid bay roof cables attach to a 108503 angled bracket secured to the rafter using a bolt and nut. Read and understand the following conditions before installing the 108503 brackets. Review connection details and Side Profile diagram for your building length in Quick Start section. Install all 108503 cable brackets once positions are determined. Standard Roof: Secure two (2) 108503 brackets there will be two per through-bolt connection (A) using the fasteners noted above. Use the pre-drilled hole at the rafter peak. No Rafter Support Kit (See Page 13): If no rafter support components are installed at the rafter where cable bracket is attached (B), secure 108503 brackets to the rafter using the fasteners noted above. Use the predrilled hole in rafter. Each (B) location will have one (1) 108503 bracket attached. Rafter Support Kit Installed (See Page 13): If rafter support kit components are installed, loosen nut and bolt at each (B) location, add the 108503 bracket, and reinstall and tighten nut. ATTENTION: The B locations are identical on opposite side of frame (not shown) on same two rafters. PROCEDURE 2: ATTACH MID BAY CABLES Complete these steps to attach mid bay diagonal cables to the installed 108503 angled cable brackets: 1. Consult table on Page 21 for cable part number. Verify on-center rafter spacing to ensure correct cable is selected. 2. Attach an AS2167 shackle to one end of the cable. 3. Fully open a turnbuckle and attach it to the free end of the cable opposite the shackle. Threads of threaded jaw should remain fully in turnbuckle body when properly opened. See below. End of Rod Body 4. Move to the frame and attach cable end with shackle to upper 108503 bracket secured to rafter (A) above. 5. Take cable end with turnbuckle and attach turnbuckle to lower 108503 bracket (B). 6. Repeat Steps 2-5 to construct and install the three (3) remaining mid bay roof cable assemblies. 7. Return to all turnbuckles and hand-tighten until snug to remove all slack. 8. Continue with the next procedure. S500_24_Wide_HT_Roll_up 23
Install Ribbon Board Optional RIBBON BOARD INSTALLATION Optional for Roll- Up Sides Gather the parts: 2" x 6" treated lumber (supplied by customer). Fasteners supplied by customer to attach boards to metal rafter pipes. Length depends on material thickness. The size and type of material you choose may require the use of alternative steps. When properly installed, the ribbon board runs the length of the frame along each side. The ribbon board is supplied by the customer as are the fasteners to secure board to the rafters. Ribbon Board The following procedure describes one way to install the ribbon boards. 1. Mark ribbon board height along the outside of the frame from end-to-end using a chalk line. Consult the diagram. 2. Align board with outer edge of end rafter and attach to the frame. Fastener heads must be flush with board surface. Countersink if needed. ATTENTION: Consult the photos on the next page for additional details. 3. Continue adding boards to complete the first run. Splices are made between rafters as shown in the baseboard procedure. Use a short section of material to secure the splice between separate boards. 4. Repeat steps to install the second run of ribbon board along the other side. 5. Continue with the installation of 111613Z144 channel. Customer-supplied Ribbon Board 24 S500_24_Wide_HT_Roll_up
Install Ribbon Board Ribbon Board Photos above show ribbon board attached to the side of an assembled frame. Example shows using 2" Tek screws (additional purchase) to secure board to rafters. Screw heads are countersunk below board surface to allow for the installation of the 111613Z144 aluminum channel. Customer-supplied exterior grade carriage bolts are also an option for fasteners. Ground level to bottom of ribbon board is 72". Ground Level Photo below shows the installed ribbon board and the installed baseboard on a sample frame. Ribbon Board Baseboard S500_24_Wide_HT_Roll_up 25
Attach 111613Z144 Channel to Ribbon Board Buildings with roll-up side panels require 111613Z144 channel for installation. The photos below show where to install the channel. Secure channel to ribbon board (if present) using FAH005B (1/4" x 2") carriage bolts, FAMF01B (1/4") fender washers, and FALB01B (1/4") nut. Install channel flush with the ends of the ribbon board and end rafters. Pre-drill bolt holes. Space fasteners at 24" on-center throughout the length of the building on both sides. If no ribbon board was installed, secure channel directly to rafters using two Tek screws per rafter. 111613Z144 Channel for Roll-Up Sides. Clamp or hold u-channel against the ribbon board and drill a 3/8" bolt hole. Channel Installation without Optional Ribbon Board Splice ATTENTION: If a ribbon board is not installed, attach the 111613Z144 channel directly to the rafters using two (2) FA4482B Tek screws at each rafter position. See photo. Attach u-channel to ribbon board using the 1/4" fasteners noted below. Splice End View FAH005B Bolt 111613Z144 Channel 5/16" Carriage Bolt (supplied by customer) 2" x 6" Ribbon Board if used. (supplied by customer) FALB01B Nut FALF01B Fender Washer Rafter Leg or Ground Post Inside of building. Channel section used for backer to join two separate channels. Do not secure two separate channels to the same rafter. Splice the channels between the rafters and use a small section of channel (or other material) as a backer. Secure using Tek screws (or wood screws if backer is wood) as shown. 26 S500_24_Wide_HT_Roll_up
Optional End Frame and Panel Installation Typically, end framing and end panels are installed before the cover is pulled onto the frame. If your building is equipped with an end wall and end wall covering, review the instructions sent with the end panel kit and end wall framing and proceed as instructed. After installing the end framing and cladding, return to this guide and continue with the installation of the main cover and roll-up sides. S500_24_Wide_HT_Roll_up 27
Attach U-Channel (111613Z144) to End Rafters INSTALL U-CHANNEL Buildings with film (or 5.2 oz) covers require double u-channel attached to end rafters to secure cover. Photos show a building with an optional end wall and roll-up panel. Additional purchase required. Secure the 111613Z144 u-channel to top of both end rafters using FA4482 Tek screws spaced at 16" on-center. Install flush with the outer edge of end rafter. See comments below for details about position of channel on end rafter. After installation, continue with the Frame Check steps on the next page. 111613Z144 Aluminum U-Channel 111613Z144 U-Channel for cover installation. Optional Poly Carbonate End Wall Cladding with End Wall Frame Ribbon Board 111613Z144 Aluminum Channel attached to the top of each end rafter flush to the outside edge of the rafter. 28 S500_24_Wide_HT_Roll_up
FRAME CHECK Frame Check Inspect the frame for sharp edges or fasteners that could damage the cover during installation. 1. Verify that all frame members are properly secured and that all bolts and clamps are tight. 2. Recheck the frame assembly for sharp edges or clamps and bolts that may interfere with the installation of the curtain. File or tape sharp edges as needed. 3. Reposition clamps and bolts as needed and tape all rafter pipe joints with duct tape to protect the cover material. 4. Verify that the main building frame is properly and adequately anchored. 5. Clear the site around the building to prepare a staging area for the cover material. 6. Continue with the cover installation steps. ATTENTION: Before you install the cover, verify that these options if present have been installed: end wall frame, door frames, and end wall cladding. Consult the documentation for those items and proceed as instructed. If these items have been installed or are not present, continue with the cover installation. S500_24_Wide_HT_Roll_up 29
Film (or 5.2 oz) Cover Installation INSTALL MAIN COVER SINGLE-LAYER FILM OR 5.2 OZ MATERIAL Continue with the following procedure. Gather the parts: Main cover and u-channel spring (#102198) for side and end rafter channels Ropes long enough to reach over the frame (provided by customer) WEAR EYE PROTECTION WHEN INSTALLING SPRING WIRE! After attaching u-channel to end rafters and along the sides, unpack the main cover and pull into place. Ropes or straps are typically used to pull the main cover onto and over the frame. WARNING: To prevent damage to the cover and to prevent serious personal injury, DO NOT attempt to install the main cover on windy or stormy days. Complete these steps. 1. Take the cover material and position it along the base of one side of the building. NOTE: Unfold the cover and locate the edge. 30 S500_24_Wide_HT_Roll_up
Film (or 5.2 oz) Cover Installation 2. Along the edge, clamp self-locking, duck-billed pliers to the cover material and tie ropes or straps to the pliers. NOTE: The ropes or straps must reach over the top of the building to the other side. The number of ropes depends on building length; use additional ropes spaced even throughout the length to prevent tearing the main cover when it is pulled into place. Clamp self-locking, duck-billed pliers along the cover edge, tie ropes or straps to the pliers, and then pull cover over the frame. 3. After tying ropes to the main cover, throw ropes over the building and pull cover into place. IMPORTANT: To prevent damage to the main cover during installation, use additional personnel and lifts as needed. 4. Center cover side-to-side and end-to-end. Some covers include additional material for the width due to standard material dimensions. This material can be removed and recycled, or it can be used by the customer. S500_24_Wide_HT_Roll_up 31
Film (or 5.2 oz) Cover Installation INSTALL MAIN COVER (continued) 5. Once main cover is in place and centered, begin at the peak of one end and install the 102198 wire spring into the channel. ATTENTION: Ensure that enough cover material is present to lock into the end rafter channel. Typically, the cover material is cut longer/wider than required to cover the building. For easier anchoring, allow approximately 10" to extend past the edge of the end rafter as the cover is anchored. Remove the ropes after the cover is secure. 6. Continue down both edges of first end rafter until main cover is secured to the first end rafter. 7. Move to the other end, pull cover tight, and repeat steps to secure cover in end rafter channel. 8. After securing cover end-to-end, move to one side and install the 102198 spring in the side u-channel. Use top channel of double aluminum channel for the main cover. NOTE: Begin at one end of channel and work toward the other. Maintain an even length working along the side. Final stretching of cover takes place when last side is secured. 9. Next, move to the remaining side, stretch the cover, and secure it in place. Pull the cover tight as the spring and insert spring into u-channel. 10. Trim excess cover material if desired. ATTENTION: Allow some material to remain. This allows easier stretching of the cover in the event that the material expands after it is installed. 11. Continue with the installation of the 111924Zxxx curtain stabilizer bar if equipped. WEAR EYE PROTECTION WHEN INSTALLING SPRING WIRE! Step 5 Step 8 Top Channel of U-Channel 32 S500_24_Wide_HT_Roll_up
Curtain Stabilizer Bar Installation CURTAIN STABILIZER BAR INSTALLATION 115287 The curtain stabilizer bar secures lower end of the roll-up side panel when it is closed (or down). Stabilizer bar is installed just above baseboard (if present), which is attached at ground level. Secure stabilizer bar to each ground post using FA4482 Tek screws. This component is not used when buildings are equipped with drop-down side panel option. Center of Ground Post 115287 Baseboard Ground Level Install bar as seen at the end rafter with optional baseboard. Ground Level Installed bar as attached to end rafter ground post. GS0049 Splice sections using Tek screws and a GS0049 splice plate. Side Views 115287 Tab Tab Baseboard No baseboard Align stabilizer bar with center of end rafter ground post to begin installation. Ground Level After installing stabilizer bar and baseboard (if used), continue by installing the roll-up side panels. S500_24_Wide_HT_Roll_up 33
Roll-Up Side Panel Installation Stabilizer bar may differ from shown in photo. 34 S500_24_Wide_HT_Roll_up
Roll-Up Side Panel Installation INSTALL ROLL-UP PANELS Film: Single roll of 108655: Field cut length in half. 5.2 oz: Two identical panels: D080H0xxxxxx. Complete these steps: 1. For film, locate the roll of 108655 film, roll it out and fold it in half (lengthwise). Cut the film in half. ATTENTION: Before cutting, measure film to verify correct amount. Film typically ships 2' longer per side (e.g., 36' building: film panel is 38' long). 2. Stretch a panel along one side of shelter and center it end-to-end. Panel will extend beyond end rafters. ASSEMBLE ROLL-UP SIDE PANEL CONDUIT Gather the parts: Pipe 1.315'' x 75'' swaged (#131S075) Tek screws (#FA4482B) The roll-up conduit assembly attaches to the bottom edge of the roll-up panel. This assembly runs the length of the frame and serves as the center pipe that the roll-up panel wraps around when it is opened for ventilation. Complete these steps to assemble the roll-up side panel conduit. 1. Locate sections of pipe (#131S075) to assemble the roll-up panel conduit. 2. Insert the swaged end of each pipe into the plain end of another pipe until conduit is assembled. 3. Secure each pipe joint with a Tek screw (FA4482B) and tape over the screw using duct tape. Construct a conduit that is longer than the building. Conduit is cut to length in a later procedure. Roll-up Panel For the 5.2 oz panel, conduit can be inserted into the panel pocket during the assembly process. 3. Using the lower channel of the double u-channel and wire spring (102198), secure one edge of film panel (or plain edge of 5.2 oz panel) to the u-channel. Lower Channel of the Double U-Channel 4. With edge secured, spread free/loose edge of panel (or pocket edge for 5.2 oz panel) out so it hangs down evenly from channel. Excess film panel can be rolled onto the roll-up conduit during the next procedure or trimmed. Do not trim too much off. 5. Continue with the following procedures to finish the roll-up side panel installation. 4. With assistance, place the assembled conduit on the lower edge of the roll-up side film. (For 5.2 oz panel with pocket, insert the conduit into pocket if this was not done during the previous step.) 5. Allow 6" of pipe to extend beyond the end rafter opposite where gearbox will be installed. Allow approximately 8" to extend beyond the end rafter at the gearbox end of the frame. 6. Cut the pipe to length at the gearbox end. ATTENTION: After conduit is cut to length, remainder of pipe is used for the remaining roll-up conduit. Count the pipes to verify that you have enough to complete the assembly of the remaining conduit. Consult the Twist-of-the-Wrist Assembly procedure on the next page for diagrams that show an assembled roll-up side. 7. Continue with the procedure that follows to attach the conduit to the roll-up side panel. S500_24_Wide_HT_Roll_up 35
Roll-Up Side Panel Installation ATTACH CONDUIT TO ROLL-UP PANEL Gather the parts: Assembled conduit from previous procedure Fabric clips #CC6212 (Divide quantity in half.) Tek screws (#FA4482B) To this point, the roll-up side panel along one side is secured to and hanging down from the double u-channel. The assembled roll-up conduit should be positioned on the free/lower end of roll-up panel or in the 5.2 oz panel pocket. 1. Roll assembled conduit onto the edge of film roll-up panel. (For the 5.2 oz panel with pocket, continue with the next step.) 2. Verify the conduit is evenly positioned; using half of the #CC6212 fabric clips and the same number of FA4482B screws, secure the panel to the conduit. Evenly space clips throughout length of conduit. CC6212 Fabric Clip Roll side panels so they wrap on the inside or underside of the panel. CC6212 Clips Ground Level Inside View NOTE: Twist the conduit in a direction that wraps the panel toward the inside of the frame. This allows water to drain off the building and roll-up panel. 3. Continue to roll the conduit until excess panel material is wound around conduit and lower edge is positioned at the base of frame. 4. Temporarily anchor conduit and panel to the frame or ground to prevent the wind from lifting it away from the frame. 5. Continue with the installation of the Twist-of-the-Wrist components. Photo above shows an assembled roll-up side panel with gearbox. The lower end of the 102570 aluminum channel is not anchored. Channel should float above the ground, but below the curtain stabilizer bar. Stabilizer bar may differ from shown in photo. 36 S500_24_Wide_HT_Roll_up
Roll-Up Side Panel Installation TWIST-OF-THE-WRIST ASSEMBLY Gather the parts: Aluminum channel (102570) and drive handle (102480) Gearbox (103496) and gearbox drive (102717) Mounting plate (103544), bearing (102569), and threaded rod (FAK26) 3/8" nuts (FALB04B) and 3/8" washers (FAME08B) 3. Select the aluminum channel, drill a 3/8" hole through the channel approximately 2" from the end, and attach a threaded rod using a 3/8" nut on each side of the 102570 channel. 2" The Twist-of-the-Wrist Assembly is designed to roll up the side panel. The following steps describe the assembly and its installation. Sample frame is shown. Threaded Rod (FAK26) End Rafter Guide Channel (102570) Double U-Channel Ground Post or Rafter Leg 4. Position the channel along the end rafter where the Twist-of-the-Wrist assembly will be located. 5. Secure upper end of the channel by drilling a 3/8" hole through end rafter and attach as shown. Lower end of channel will "float" and is not attached. End Rafter Gear Box (103496) Roll-Up Side Conduit Top View Carriage Bolt Baseboard 1. Measure 1/2" in from the end of the roll-up conduit, center-punch the location on the pipe, and drill a 5/16" hole through the conduit. 2. Insert a tubing adapter into the conduit and align the holes of the adapter with the drilled holes in the conduit. 1/2" Do not allow channel to contact ground. Use position of roll-up conduit, which is at the base of frame along the side, to help align channel when securing it in place. S500_24_Wide_HT_Roll_up 37
Roll-Up Side Panel Installation TWIST-OF-THE-WRIST ASSEMBLY (continued) 6. Select the bearing bracket and attach the bearings as needed. (In some instances, the bearings may come already attached.) Assemble as follows if needed: 10. Attach the Twist-of-the-Wrist gearbox to the mounting plate using hex head bolts. NOTE: Single bearings are attached to the sides of the bracket and double bearings to the middle portion of the bracket. Use 1/4" hex bolts and locknuts as needed. Install a flat washer on both sides of each bearing to insure proper operation of bearings and the assembly. 7. Install the longer bolts with bearings on the side of the bracket that has the two holes. Install these before installing the double bearing assembles. See the figures below. 8. For the spacers on the long bolts, insert a 5/16" nut over each bolt. These nuts are used as spacers only. 5/16" Nut 11. Using a 1/4" x 2" carriage bolt (FAH005B) and nut (FALB01B), attach the square shaft to a tubing adapter. 5/16" Nut 9. Slide the Twist-of-the-Wrist mounting plate over the long bolts and secure the plate with two lock nuts. 12. Slide the square shaft through the Twist-of-the-Wrist gearbox. Lock Nuts 38 S500_24_Wide_HT_Roll_up
Roll-Up Side Panel Installation TWIST-OF-THE-WRIST ASSEMBLY (continued) 13. Slide the Twist-of-the-Wrist assembly onto the aluminum channel from the ground end. (This is the free end of the channel.) INSTALL THE ANTI-BILLOW ROPES The anti-billow rope is installed along the outside of the frame and stretches between the ribbon board and the baseboard. When installed correctly, the anti-billow rope helps keep the roll-up panel in place when it is fully or partially closed. Use the diagram as a guide and complete the steps to install the anti-billow rope. 1. Beginning at one end rafter, take two (2) eye screws (FA2155) and attach one to the baseboard and one to the ribbon board. Align the FA2155 eye screws with each other. See circles below. ATTENTION: If a baseboard is not present to mount the eye screws, purchase eyebolts locally to mount to the individual rafter legs/ground posts. 14. Using the conduit as a guide, adjust the aluminum channel on the threaded rod so the channel runs parallel with the end rafter. In some instances, you may need to trim the conduit. 15. Attach the roll-up conduit to the square shaft of the assembly by inserting a 1/4" x 2" carriage bolt (FAH005B) through the hole in the conduit and tubing adapter. Tighten the nut. FA2155 Eye Screws 2. Using the sample diagrams as guides, move to the next rafter and attach the eye screw to either the baseboard or the ribbon board, depending on the desired pattern. 3. Continue installing eye screws until reaching the other end rafter and finish installation by repeating Step 1. 16. Test the operation of the Twist-of-the-Wrist assembly and repeat the steps for the remaining assembly. NOTE: If cover rolls in desired direction, but you want to turn crank in the opposite direction for the same result, unbolt, reposition/flip gearbox, and remount it on the same side of the mounting bracket. 17. Repeat the steps to install the remaining roll-up panel and Twist-of-the-Wrist Assembly. 18. Once both assemblies are installed, continue with the installation of the anti-billow rope. 4. Take one end of the bulk roll of rope, thread it through the eye screws, and secure the end to an eye screw. 5. Move to the other end of the rope, pull to remove slack, and cut to length. Tie the end to the eye screw. 6. Test the roll-up panel operation and adjust rope if it interferes with the curtain. 7. Repeat for the remaining roll-up side panel. 8. Read the shelter care and maintenance information. S500_24_Wide_HT_Roll_up 39